The document provides an overview of ORNL's automotive research capabilities across several areas: 1) It describes ORNL's research programs in electrification, efficient vehicles, alternative fuels, intelligent systems and new transportation technologies and processes. 2) Several key facilities are highlighted including a power electronics lab, vehicle systems integration lab, battery manufacturing facility, and manufacturing demonstration facility. 3) Specific projects involving neutron imaging of diesel particulate filters, high performance computing simulations, and development of a planar bond all power module and flux coupling motor without permanent magnets are summarized.

1. ORNL Automotive
PEEM Capabilities
Mitchell Olszewski
Oak Ridge National Laboratory
Presented to Drive Oregon
November 7, 2013

2. “All of the Above”
The present ORNL R&D Program
Accelerating
electrification
• Wireless
power transfer
• Advanced
battery
materials,
processing,
and modeling
• Battery
manufacturing
R&D
• Fuel Cells
Efficient
vehicles
Alternative
• Lightweighting fuels
• Advanced
• Renewable
combustion/
fuels for
electric power
advanced
train
engines
technology
• Drop-in
• Trucks as well
biofuels for
as autos
legacy cars
• Sustainability
analysis
• Natural gas
Intelligent systems
and operations
• Efficient
operations in
commercial
vehicles
• Data for decisionmaking
• Managing
congestion
• Communications
New technologies
and processes for:
• Safe, secure, and
affordable vehicles
for passengers
and freight
• Domestic production
of transportation fuel
• Reducing
environmental impacts
of transportation
• Predictable, reliable
transport schedules

3. We support two national GovernmentIndustry Partnerships in Transportation
Partners:
Associate Members at the Technical Level
www.vehicles.energy.gov/about/partnerships/
usdrive.html

4. Power electronics lab
expands wireless charging
and WBG evaluations
• Stationary and dynamic
wireless power transfer
technology at the
prototype vehicle scale.
Recent award from DOE
for further development.
• Performance
verification of
new WBG
devices; new
power
electronics
topologies and
packages that
make full use of
WBG attributes.

5. Vehicle Systems Integration Lab unique in
DOE system
Highly flexible powerpack research lab large enough for HD vehicles
• Current CRADA partner Meritor with
participation from Cummins
• Hybrid powertrain development
• Integrates engine and emission
data with modeling, simulation, and
analysis
• Support R&D to accelerate
calibration methods
Enables system-level
research for advanced
combustion, electric
drive, controls, and
fuels research within
applicable emissions
constraints.

6. Battery Manufacturing Facility, companion labs
Exceptional capabilities will yield success in energy
storage
• Lower cost, faster
manufacturing methods for
Li-ion. Successes
emerging.
• Improved materials
• Modeling for better design
and systems performance
• Neutron beam studies
• New chemistries like Li-S
• Non-mobile applications
Rechargeable battery
Voltage: 3.7-4.5V
Capacity: 100mAh-7Ah

7. Defining Strengths in Intelligent
Transportation Systems
• Cars that “think”— new sophistication
of vehicle controls
• Cyber-security
• Big data sciences, managing and
using the data load from connected
vehicles (V2x)
• Increasing vehicle autonomy
• Wireless charging
• Sustainable Communities Strategies,
analysis, next version of FE.gov

8. Manufacturing Demonstration Facility (MDF)
A great resource and partner to Transportation
There is a manufacturing element in biomass and fuel cell programs
in EERE.
Focus on additive manufacturing, lightweight materials processing, carbon fiber.
User program in place. Co-located battery manufacturing lab.
• Additive manufacturing (part photo below)
• Processing functional materials, light metals
• Carbon fiber and composites, links to CFTF

9. Initial success with HFIR imaging beam
Neutron imaging complements optical and x-ray methods
• Current focus on diesel particulate filters (DPFs)
– Improve understanding of regeneration behavior
– Improving understanding of ash build-up
– Aids validation of full-scale modeling
• EGR cooler fouling project enhanced with neutron
imaging and data reconstruction
– Full size coolers imaged at HFIR
• Expanding role in diesel fuel injectors
– Internal and external dynamics, and their
relationships
– Cavitation and durability issues
• Imaging experiments with battery processes.
Augments diffraction experiments at VULCAN beam.

10. Engaging high-performance computing
to accelerate design and deployment
New user project business model offers advantages to industry for
proprietary work
• Collaboration with Ford examines stochastic and
deterministic processes that drive cycle-to-cycle instabilities.
• Collaborations with GM to improve the understanding and
design optimization of gasoline fuel injector hole patterns.
• Open architecture software for computer aided engineering
for batteries to facilitate rapid battery design and prototyping
by integrating battery modeling components.
T
312.6
301.6
Highly-resolved simulations of
cylindrical cell with coupled
electrochemical, electrical, and
thermal processes showing
temperature distribution in the
cell.

11. PEEM R&D Capabilities
Power
Electronics
• Circuit Topologies
• Integrate functionality and reduce capacitance
• Packaging
• Increase efficiency and improve heat removal
• Wide Bandgap Devices
• Increase efficiency and temperature tolerance
• Charging
• Wireless charging for static and dynamic
applications
• Advanced Manufacturing
• New designs possible
Electric
Motors
• Non-Permanent Magnet Motors
• Eliminate costly rare earth magnet material
• Advanced Materials
• Use for laminations, etc. to improve efficiency

12. Inverter Development Addresses Near
Term Application Leading to
Transformational
Minimal Changes from OEM way of business for near-term
• Segmented inverter can be applied now with minor winding changes in motors (reduces
capacitors by 60%)
Changes from OEM way of business for transformational
• Current Source Inverter reduces capacitance requirement by 90%, decreases cost by
eliminating needs for diodes and integrating boost function and charger into inverter
– Near- to Mid-term application: need multiple sources for reverse blocking IGBTs
– Transformational: use WBG frequency and efficiency to reduce cost
• ZCSI adds charging functionality to CSI
• Reactive Power Inverter and other inverter concepts – take advantage of new switches and
materials

13. Planar_Bond_All Power Module
Characterization
PBA Module
200
500
450
ΔVce(PB)=72V
160
400
140
350
120
Ice
100
Vce
300
250
80
200
60
150
40
100
20
Voltage (V)
Current (A)
Wire Bond Module
ΔVce(WB)=156V
180
Advancement of PBA
packaging technology
and power modules:
50
0
0
500
1000
1500
0
2000
Time (nS)
0.6
Thermal
Resistance
θja,sp
0.4
29.1%
0.2
0
Specific Thermal
resitance (Cm2.C/W)
NissanLeaf
0.52
ToyotaPrius10 PlanarBondAll
0.471
0.334
ü Decreased package thermal
resistance by 30%;
ü Decreased package
parasitic electrical inductance
by 75%, and electric
resistance by 90%;
ü Reduced the major
packaging manufacturing
steps from five (5) to two (2);
ü Achieved more than 30%
volume, and weight
reduction.

14. Novel Flux Coupling Motor Without
Permanent Magnets
Status
Objectives
• Develop a traction motor without rare earth
permanent magnets (PMs) achieving specific
power and power density similar to PM
machines but at lower cost and with higher
efficiency.
• Significant advances have been accomplished
in the simulation and design proving the
feasibility of meeting DOE’s 2020 motor power
density target.
• Work is ongoing to reduce costs and volume to
achieve 2020 targets.
• A breakthrough on the mechanical design was
achieved allowing the rotor to safely operate at
14,000 RPM.
Projected Benefits
• Concept achieves the benefits of PM machines
without rare earth magnets
- Reducing dependency on China for rare
earth materials
- 20% cost reduction, based on present
material costs
- 3% overall efficiency increase due to
adjustable field
- Free from temperature restrictions of PM
materials
Camry
Novel Machine
2020 Target
Max. power
output
70 kW
(tested)
115 kW (computed)
55 kW
Weight
36.3 kg
55.7 kg
34.38 kg
Volume
13.9 Liters
13.6 Liters*
9.65 Liters
kW/kg
1.9 kW/kg
2.1 kW/kg
1.6 kW/kg
kW/l
5.0 kW/l
8.5 kW/l
5.7 kW/l
Power factor
0.61 – 1.00
0.75 – 1.00
Cost
**10.7 $/kW
( $749 for 70 kW)
***6.1 $/kW
( $702 for 115 kW)
4.7 $/kW
( $259 for 55 kW)

15. Thank You